E-plastics breakthrough opens door to easy disassembly

The Dutch TNO research institute has developed a new disassembly method for end-of-life electronics.

The innovation will make it a lot easier to take apart e-scrap with integrated plastics. This is accomplished thanks to a water-based layer that can be inserted between the components and outer plastic layer.

This is a major step forward, given the e-plastics market was worth almost EUR 35 billion in 2023. Meanwhile, the volume of e-scrap out there is expected to reach 75 million tonnes by 2030 and 110 million tonnes by 2050.

No longer shredded

Printed electronic components and interconnects are encased in plastics for protection. Unfortunately, this makes repair and recycling nearly impossible, resulting in these hybrid electronics being shredded or incinerated.

This process contributes to additional CO2 emissions and the loss of valuable raw materials.

TNO has conducted tests that demonstrate that the water-based layer is strong enough to withstand 1000 hours of humidity up to 85% and a temperature of 85 degrees Celsius.

Researchers point out that the new material enables efficient removal of all plastic without damaging the electronic circuitry. It’s also possible to remove, repair and replace faulty components before reapplying the plastic.

Seamless and recycling-friendly

The research institute observes that companies are increasingly using printed forms of electronics due to their seamless integration into most products. Citing a recent study, it estimates printed electronics market is currently worth over EUR 160 million. This will reach EUR 3 billion by 2032.

Besides phasing out buttons and switches, electronics with integrated plastics weigh less and are faster to produce. Popular applications include wearable medical sensors and car dashboards.

TNO argues increasing the recycling and repair of electronics will yield significant cost savings and more efficient use of materials. This, in turn, will help reduce waste and enable more sustainable production methods in compliance with rules on ecodesign and the Sustainable Products Regulation.

The work has been published in the Journal of Cleaner Production.